So after looking at all of the amazing builds here on OFN for the last year or so I decided that it was time for me to get off my butt and get a build thread up for my Postal Jeep project (PJ for short)

Originally the PJ had 4 wheel drum brakes, which as some of you may know can be SCARY as hell to stop with. So I decide that I should start rebuilding the brake system.

I started with the pivot for the pedal it's self. 30 years of use and NO maintenance makes for a little bit of slop. I fabbed up a new pivot out of steel, with some naval bronze for the bearing.....

This is old and new side by side, not even comparable.

I ended up reworking the cross shaft as well adding a thrust bearing, in between the pedal and the mount....

also ended up threading the old push rod into the master cylinder and adding a heim on the end.

From there it was onto the front brakes. I knew that I wanted BIG discs, but was not too sure how to go about it. I did some research, came across a couple of people making bolt on kits, but they were wanting $100 bucks or more for the caliper brackets.

After some measuring, I thought, "this can't be too hard...." I bought some 3/4" plate and did some after hours work, at the machine shop that I was working at, at the time.

So this is what the brackets looked like after a couple of hour of work.

As for rotors, I ended up using '87 CJ-7 rotors, with the thru hole opened up by about .150", and the front hub being turned down by about .200".

Once this thing is drivable, I would like to go back and make rotor hats, so that I can use rotor blanks, instead of custom machining rotors every time I wear a set out.

I ended up going with '69-'77 GM calipers, as they were inexpensive and there are a few bolt upgraded versions for future improvements.

Also added a .250" wheel spacer to all four corners, thinking that any additional width would help.....

Ended up finishing off the front with AN adapters and braided kevlar lines from Speedway.....

The rears are staying stock drums for now, but may get a disc upgrade once the PJs drivable.

I ended up going back just recently and replacing the VERY worn factory hard lines with kevlar AN lines through out and adding residual pressure valves to both the front and rear.

Interesting build thread... the guy across from my shop has 2 DJ's, I've been trying to score ... but he is a major Hoarder ... took some pixs but hard to see with all the junk around them.... (I'm still trying LOL)

From there I ended up adding one more at the bottom rear of the notches, both for support and as a place to hang a rear sway bar from.

The sway bar, is off of a 1985 Toyota Celica. I have both of the stock bars, front and rear, and came to the conclusion that they would be perfect for the PJ as it should weight, hopefully half what the Celica does.

After that I worked on the placement of a track bar for the rear axle

And the frame side mount....

I know that a track bar is overkill for a leaf spring rear end, but with wider rubber and some possible auto crossing in the PJs future I decided that it wouldn't hurt.

The track bar has a heim on one end and poly bushing on the other.

From there I pulled the shackles and made some room to paint. I use POR-15 on the frame.

And then dropped it back down to assemble with some temporary shocks.

I also added a couple of details to the rear frame boxing a welded in ground lug, for the relocated battery, and a water jetted reaper logo I designed a while back.

Nice! I've been thinking about doing a CJ5 hot rod with leftover parts from my junk. I've got a good chunk of the parts needed, I think I'm gonna sit back and see what you do on this one and kinda copy you.